Sterile battery charging device

ABSTRACT

A sterile battery charging device and assembly for charging within a sterile field. The battery charging assembly includes a base unit having a first interface and a second interface. The assembly additionally includes a high capacity battery connectable to the first interface and a low capacity battery connectable to the second interface. The base unit retrieves power from the high capacity battery and transmits power to the low capacity battery. The high capacity battery and the low capacity battery are interchangeably connectable to the base unit.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a national stage application under 35 U.S.C. 371based on international patent application PCT/US20/20105 filed on Feb.27, 2020, which claims priority to and the benefit of U.S. ProvisionalPatent Application Ser. No. 62/790,076 filed on Jan. 9, 2019 andentitled “Sterile Battery Charging,” and U.S. Provisional PatentApplication Ser. No. 62/812,276, filed on Mar. 1, 2019 and entitled“Sterile Battery Charging,” the entireties of which are incorporatedherein by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to surgical power systems and, moreparticularly, to a sterile battery charging device and assembly.

2. Description of Related Art

Batteries used to power surgical equipment are typically sterilizedprior to use so they can be used in the sterile field. When a batteryruns out of power, it is replaced with a new battery. For smallerequipment, the battery life may be unreasonably short, requiringreplacement of one or more times during the surgery. As this can betime-consuming, it would be useful to recharge the battery duringsurgery when the surgical instrument is not in use. This wouldeffectively extend the runtime of the surgical instrument before thebattery needs replacing.

Placing a corded battery charger in the sterile field to accomplish thistask presents several undesirable challenges. The power cord connectedto the charger and plugged into a power outlet can present a trippinghazard for people (e.g., surgeons and surgical nurses) are regularlywalking between the sterile field and wall. The other challenge is withthe sterile field itself. Having a power cord that runs between thesterile charger and the non-sterile power outlet presents an opportunityfor contamination.

Therefore, there is a need for a self-contained battery charger with noexternal connections.

Description of the Related Art Section Disclaimer: To the extent thatspecific patents/publications/products are discussed above in thisDescription of the Related Art Section or elsewhere in this disclosure,these discussions should not be taken as an admission that the discussedpatents/publications/products are prior art for patent law purposes. Forexample, some or all of the discussed patents/publications/products maynot be sufficiently early in time, may not reflect subject matterdeveloped early enough in time and/or may not be sufficiently enablingso as to amount to prior art for patent law purposes. To the extent thatspecific patents/publications/products are discussed above in thisDescription of the Related Art Section and/or throughout theapplication, the descriptions/disclosures of which are all herebyincorporated by reference into this document in their respectiveentirety(ies).

BRIEF SUMMARY OF THE INVENTION

Embodiments of the present invention are directed to a sterile batterycharging device and assembly for charging within a sterile field.According to one aspect, the device includes a base unit having a firstinterface and a second interface. The first interface is configured toreceive a first battery and the second interface is configured toreceive a second battery. The base unit retrieves power from the firstbattery and transmits power to the second battery. The first battery andthe second battery are interchangeably attachable to the base unit.

According to another aspect, the assembly includes a base unit having afirst interface and a second interface. The assembly additionallyincludes a high capacity battery connectable to the first interface anda low capacity battery connectable to the second interface. The baseunit retrieves power from the high capacity battery and transmits powerto the low capacity battery. The high capacity battery and the lowcapacity battery are interchangeably connectable to the base unit.

According to yet another aspect, the present invention is a method forcharging surgical batteries. The method includes the steps of: (i)providing a base unit with power in a sterile field; (ii) sterilizing abattery; (iii) introducing the battery into the sterile field aftersterilization; (iv) charging the battery with power from the base unitin the sterile field; (v) using the battery in a surgical procedure inthe sterile field; and (vi) recharging the battery with power from thebase unit in the sterile field.

These and other aspects of the invention will be apparent from andelucidated with reference to the embodiment(s) described hereinafter.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

The present invention will be more fully understood and appreciated byreading the following Detailed Description in conjunction with theaccompanying drawings. The accompanying drawings illustrate only typicalembodiments of the disclosed subject matter and are therefore not to beconsidered limiting of its scope, for the disclosed subject matter mayadmit to other equally effective embodiments. Reference is now madebriefly to the accompanying drawings, in which:

FIG. 1 is a perspective view schematic representation of a base unit,according to an embodiment;

FIG. 2 is a perspective view schematic representation of an adapterconnected to the base unit, according to an embodiment;

FIG. 3 is a perspective view schematic representation of a low capacity(instrument) battery connected to the adapter of FIG. 2 ;

FIG. 4 is a flowchart of a wireless charging platform, according to anembodiment;

FIG. 5 is a flowchart of a wireless charging method, according to anembodiment;

FIG. 6 is a perspective view schematic representation of a surgicalpower system, according to an embodiment;

FIG. 7A is a perspective view schematic representation of a highcapacity battery sliding into the base unit, according to an embodiment;

FIG. 7B is a perspective view schematic representation of the highcapacity battery connected to the base unit, according to an embodiment;

FIG. 8 is a perspective view schematic representation of high capacitybatteries, according to an exemplary embodiment;

FIG. 9 is perspective view schematic representation of a high capacitybattery attached to a large surgical instrument, according to anexemplary embodiment;

FIG. 10 is perspective view schematic representation of the adapter ofFIG. 2 ; and

FIG. 11 is a perspective view schematic representation of a low capacitybattery, according to an exemplary embodiment.

DETAILED DESCRIPTION OF THE INVENTION

Aspects of the present invention and certain features, advantages, anddetails thereof, are explained more fully below with reference to thenon-limiting examples illustrated in the accompanying drawings.Descriptions of well-known structures are omitted so as not tounnecessarily obscure the invention in detail. It should be understood,however, that the detailed description and the specific non-limitingexamples, while indicating aspects of the invention, are given by way ofillustration only, and are not by way of limitation. Varioussubstitutions, modifications, additions, and/or arrangements, within thespirit and/or scope of the underlying inventive concepts will beapparent to those skilled in the art from this disclosure.

Referring now to the figures, wherein like reference numerals refer tolike parts throughout, FIG. 1 shows a base unit 12 of a sterile batterycharging device 10. The base unit 12 is shown removably attached orfixed to a surgical power system 14. An exemplary surgical power system14 is the Hall® Powered Instrument System. In the depicted embodiment,the surgical power system 14 is a Hall® Lithium Charger (FIG. 6 ). Thesurgical power system 14 has one or more base units 12 connectedthereto. According to an embodiment wherein the surgical power system 14is the Hall® Lithium Charger, there are four base units 12 connected tothe Hall® Lithium Charger 14, as shown in FIG. 6 . The surgical powersystem 14 can be positioned on a table-top or wall-mounted for surgicalprocedures.

Still referring to FIG. 1 , the base unit 12 is substantially planar andrectangular. In the depicted embodiment, the base unit 12 has a plate 16connected to a surface 18 of the surgical power system 14. The base unit12 additionally includes a first interface 20 and a second interface 22.The first interface 20 is used to connect to a high capacity battery 24for retrieving power from the battery 24. Thus, the first interface 20is used as the power source of the sterile battery charging device 10and is responsible for providing the charging power. The secondinterface 22 is used to connect to a low capacity battery 26. As aresult of the interchangeable attachment of the high capacity battery 24and the low capacity battery 26 to the base unit 12, power can be pulledfrom the high capacity battery 24 and then transferred to the lowcapacity battery 26.

In an embodiment, the first interface 20 is one or more battery rails.Specifically, as shown in FIG. 1 , the first interface 20 is a pair ofspaced battery rails connected to the plate 16 of the base unit 12. Thebattery rails 20 extend substantially parallel to each other alongand/or over the plate 16 of the base unit 12. The battery rails 20 aredesigned to connect to the sterilizable, high capacity battery 24. Highcapacity batteries 24 are used with large surgical instruments, such asa saw handpiece. They provide consistent, long-lasting power for largebone and total arthroplasty procedures. Exemplary sterilizable, highcapacity batteries 24 are shown in FIG. 8 . The high capacity battery 24(including the embodiment shown in FIG. 8 ) is fully autoclavable andcan be a Lithium battery.

In order to pull power from a high capacity battery 24, the highcapacity battery 24 is attached to the base unit 12. Specifically, asshown in FIGS. 7A and 7B, the high capacity battery 24 slides betweenthe battery rails 20 on the base unit (FIG. 7A) until the high capacitybattery 24 locks into place or otherwise achieves a draining/chargingposition on the base unit 12 (FIG. 7B). The battery rails 20 hold thehigh capacity battery 24 in place while the base unit 12 pulls powerfrom the high capacity battery 24.

Still referring to FIG. 1 , the second interface 22 is one or morebattery contacts. In the depicted embodiment, there are two batterycontacts 22 on the base unit 12. The battery contacts 22 are adapted toconnect to the sterilizable, low capacity battery 26. Low capacitybatteries 26 are used with small, precise surgical instruments, such asdrills, shaver blades, and burs. These low capacity batteries 26 arecompact and lightweight. They provide strong, reliable power forsurgical procedures including small bone, sports medicine, and lighttrauma. An exemplary sterilizable, low capacity battery 26 is shown inFIG. 11 . The low capacity battery 26 (including the embodiment shown inFIG. 11 ) is fully autoclavable and can be a Lithium battery.

In an alternative embodiment, the base unit 12 is adapted for wirelesscharging (e.g., inductive charging via a primary coil in the base unit12). (A secondary coil would extend through the low capacity(instrument) battery 26, as understood by a person of ordinary skill inthe art). Using wireless charging is advantageous as the low capacity(instrument) battery 26 may stay connected to the surgical instrument(e.g., shaver blade) during charging. The surgical instrument withconnected low capacity (instrument) battery 26 must simply be placed inproximity to the sterile battery charging device 10 (i.e., base unit 12)for charging to occur.

Turning now to FIG. 4 , there is shown a flowchart of a wirelesscharging platform 100, according to an embodiment. A wireless chargingplatform 100 may be powered by a Universal USB 102, a common walladapter power supply (e.g., AC-DC) 104, a rechargeable battery powerbank 106, or a stand-alone power supply integrated into platformhardware 100A. The aforementioned power source alternatives providepower to the wireless charging platform 100 via a wireless platformpower input 108. While this technique may involve the use of cables orwires, it allows the flexibility to use various input powerarrangements. The platform hardware may be incorporated into supportdevices, such as surgical tables and instruments stands (e.g., Mayostand), for example. Wireless charged accessories may include (but arenot limited to): battery powered foot controls, tablets and/or laptopsin sterile use, remote controls for console controls (e.g., cameras,pumps, light sources), and surgical lights and LEDs (e.g., handpiecelighting, helmets, and space suits).

A method 200 for wireless charging in a sterile field is shown anddescribed with reference to the flowchart in FIG. 5 . First, anon-sterile battery (or other power source), such as one of the high andlow capacity batteries 24, 26, is obtained (step 202) and cleanedoutside the sterile area (at step 204). The battery 24, 26 can then becharged outside the sterile field (step 206). Thereafter, the battery24, 26 is sterilized (step 208). Sterilization can be completed using anautoclave or any other comparable, approved sterilization techniques.After sterilization, the battery 24, 26 is charged in the sterile fieldwhen in chargeable proximity to the base unit 12 (step 210). Thereafter,the battery 24, 26 can be used for a surgical procedure (step 212). Whenthe battery 24, 26 has low power or otherwise has low energy levels, thebattery 24, 26 is placed within chargeable proximity to the base unit 12to recharge within the sterile field (steps 214, 210).

Alternatively, a battery pack could be reduced in physical size throughuse of a hybrid power system. A hybrid power system incorporates asmaller rechargeable cell or battery with a super capacitor boostcircuit connected to the cell or battery. The super capacitor can becharged at a fast rate (<10 seconds) when compared to the rechargeablecell or battery. This type of powered surgical system could be chargedon top of a typical instrument stand with the charger platform.

Turning now to FIG. 2 , there is shown a perspective view schematicrepresentation of an adapter 28, according to an embodiment. The adapter28 allows for connection of the low capacity battery 26 to be charged(as may be necessary; low capacity battery 26 can directly connect inanother embodiment). In the embodiment shown in FIG. 2 , the adapter 28is a L3500 Small Bone Lithium Power Adapter (FIG. 10 ). The adapter 22is configured to connect with the low capacity battery 26 for charging.In the embodiment shown in FIG. 10 , the L3500 Small Bone Lithium PowerAdapter 28 is adapted to connect to a sterilizable, low capacity(instrument) battery 26 such as that shown in FIG. 11 .

Referring now to FIG. 3 , there is shown a perspective view schematicrepresentation of the low capacity battery 26 connected to the adapter28. A partially discharged low capacity (instrument) battery 26 isconnected to the adapter 28, initiating the charging effect. In anembodiment, the high capacity battery 24 is drained as the low capacitybattery 26 is charged due to the number of base units 12 attached andavailable on the surgical power system 14. Multiple high capacitybatteries 24 may be used to increase the runtime of one low capacitybattery 26. Or, multiple low capacity batteries 26 may be charged at onetime. The connection to the low capacity battery 26 may be through aphysical connection (e.g., pins on the base unit 12) or through awireless connection. A wireless connection does not require the lowcapacity battery 26 to be removed from the surgical instrument whereasthe wired connection does.

The advantage of using an existing high capacity battery 24 as a chargerpower source is twofold. First, the high capacity battery 24 is alreadyavailable due to its use in complimentary devices. Second, it isdesigned to be sterilized. Thus, the number of batteries 24, 26 used forsurgery can be lowered as a depleted battery 24, 26 can be replaced witha charged battery 24, 26, decreasing the time required to changebatteries 24, 26, which interrupts surgery.

While embodiments of the present invention has been particularly shownand described with reference to certain exemplary embodiments, it willbe understood by one skilled in the art that various changes in detailmay be effected therein without departing from the spirit and scope ofthe invention as defined by claims that can be supported by the writtendescription and drawings. Further, where exemplary embodiments aredescribed with reference to a certain number of elements it will beunderstood that the exemplary embodiments can be practiced utilizingeither less than or more than the certain number of elements.

What is claimed is:
 1. A battery charging device, comprising: a numberof base units each having a first interface and a second interface, thefirst interface configured to receive a first battery and the secondinterface configured to receive a second battery; a first of the numberof the base units is configured to retrieves power from the firstbattery wherein when the first battery is attached to a second of thenumber of the base units and transmits power to the second batterywherein when the second battery is attached to the first of the numberof the base units; and both the first and second interfaces of each ofthe number of base units are located on a position where the firstbattery and the second battery are interchangeably attachable.
 2. Thedevice of claim 1, wherein the base unit is substantially planar.
 3. Thedevice of claim 1, wherein the base unit is substantially rectangular.4. The device of claim 1, wherein the first interface is a pair ofspaced and substantially parallel rails extending along each of thenumber of base units.
 5. The device of claim 4, wherein the firstbattery is slidable within the pair of spaced and substantially parallelrails.
 6. The device of claim 1, wherein the second interface is one ormore battery contacts.
 7. The device of claim 1, wherein the first andsecond batteries are sterilizable.
 8. A battery charging assembly,comprising: a number of base units each having a first interface and asecond interface; a high capacity battery connectable to the firstinterface; a low capacity battery connectable to the second interface; afirst of the number of the base units is configured to retrieves powerfrom the high capacity battery wherein when the high capacity battery isattached to a second of the number of the base units and transmits powerto the low capacity battery wherein when the low capacity battery isattached to the first of the number of the base units; and both thefirst and second interfaces of each of the base units are located on aposition where the high capacity battery and the low capacity batteryare interchangeably connectable.
 9. The assembly of claim 8, furthercomprising an adapter connected between the second interface and the lowcapacity battery.
 10. The assembly of claim 9, wherein the low capacitybattery is an instrument battery connectable to the adapter.
 11. Theassembly of claim 8 wherein the first interface is a pair of spaced andsubstantially parallel rails extending along each of the number of baseunits.
 12. The assembly of claim 11, wherein high capacity battery isslidable within the pair of spaced and substantially parallel rails. 13.The assembly of claim 8, wherein the second interface is one or morebattery contacts.
 14. The assembly of claim 8, wherein the high capacitybattery and the low capacity battery are sterilizable.